deliverable “stakeholders conference” d … · deliverable “stakeholders conference” d 7.3...

ELIBAMA – European Lithium-Ion Battery Advances MAnufacturing CONFIDENTIAL Deliverable D7.3 page 1

DELIVERABLE “STAKEHOLDERS CONFERENCE” D 7.3 Version 0

Project number: FP7-2011-GC-ELECTROCHEMICAL-STORAGE Duration of the project: 36 months Project Co-ordinator: Renault Work Package and Task: WP7 Main Author: Jérôme PEYRARD Contributors: All partners Nature: Other Dissemination level: PU Due delivery date: t0 + 36 Actual delivery date: t0 + 36

Abstract At the end of the project, a stakeholder conference has been organized by the project’s partners in order to present to the community the key findings of the ELIBAMA project. This event took place in Newcastle on the 14Th of September 2014.

Contents 1. Preparation and advertising of the event The effective preparation of the Stakeholders conference started during the M30 Steering Committee meeting where the first draft of the agenda of the day was validated and some dates and locations proposed. 1.1. Agenda In addition to the presentation of the key findings, some timeframes have been reserved to external speakers in relationship with the battery manufacturing:

- Claude Chanson from the Recharge Association presented “The challenges for the Battery Industry development for E-mobility in Europe”

- Iosu Cendoya from Cidetec made a presentation of GreenLion project progress

- Gaetan Patry from Renault highlighted the challenges of “an automotive battery industry in Europe” seen from the costs point of view

- Pierrot Attikedou from Newcastle University draw a picture of the different research fields in the battery domains.

At the end, the agenda was finalized end August.


1.2. Technical content A template of presentation has been prepared including for each manufacturing process:

- A short SOA introduction - A description of the ELIBAMA’s breakthroughs - Some perspectives for the future

9 technical presentations of 20 mn have been prepared by the different partners. 1.3. Advertising of the event A communication package have been prepared and dispatched with the first invitations in July 2014. E-mails to around 500 potential attendees (consolidated from the different partners’ network) have been sent. In parallel, the conference has been advertised:

- on the ELIBAMA website

- on some partners websites (PE, …) - on EGVI website - during some other events (EUCAR, …)

At the end 56 persons confirmed their interest in attending the conference.


2. The stakeholders conference Organized by UNew, the conference took place in Newcastle upon Tyne on the 14th of September gathering more than 50 attendees from 40 companies.

It enables to share the findings coming from the ELIBAMA project but also to discuss the challenge of a European industry of Li-ion batteries. 3. Results After the meeting, all the presentations have been made available to the Stakeholders on the project’s Website:

http://elibama.wordpress.com/stakeholders-conference/ Up to now, this page counts 292 views. The level of satisfaction for the conference (measured by an on-line poll) is very good as more than 80% of the participant rated the conference 8 or above (on ten). A questionnaire has also been set-up to identify the most interesting research fields for the future among those presented (in order to prepare future cooperations):


4. Annex: detailed agenda

ELIBAMA stakeholders’ conference – Agenda

9:30 am Arrival and Coffee

9:50 am Introductions

• The challenges for the Battery Industry development for E-mobility in Europe (C.Chanson

- Recharge)

• ELIBAMA project overview: from raw materials to manufacturing (J.Peyrard – Renault)

• Advanced manufacturing processes for Low Cost Greener Li-Ion batteries: : the

GREENLION project (I.Cendoya – IK4 - Cidetec)

• University of Newcastle : overview of the Li-Ion batteries research fields (P.Addidekou-

UNew)

11:00 am Coffee break

11:15 am Innovative electrode materials and manufacturing processes

• Special 3D copper foils to lower production costs for batteries (H.Holeczek - Fraunhofer

IPA)

• Green PVDF binder for green batteries (M.Stanga - Solvay)

• The challenge of an aqueous based and solvent free electrode coatings (A.Glawe -

Kroenert, J.Breger – SAFT, J.Peyrard - Renault, M.CUdazzo - Fraunhofer)

12:35 pm Lunch and exhibition

01:35 pm Innovative cells manufacturing processes

• LiTFSI against LiPF6 : a losing battle ? (F.Metz - Solvay)

• Assembly and Joining of Li-Ion-Cell Sheet-Stacks (D.Lindenau-Daimler)

• Process cleanliness control in Li-ion battery manufacturing: Impact of filtration and

purification solutions on battery production (C.Herriot-Entegris)

• A Rapid Non-Destructive Testing Technique for Li-Ion Battery Quality Control

(M.Armstrong – University of Newcastle)

03:05 pm Coffee break

03:20 pm Eco-design tools and batteries end of life management

• Life-Cycle Assessment in Lithium-ion batteries (M.Gama – PE INTERNATIONAL)

• Toward an efficient batteries recycling process (R.Laucournet - CEA)

04:00 pm Conclusions

• An automotive battery industry in Europe : a chance to take (G.Patry – Renault)

04:30 pm End of the conference

ABSTRACTS:

Introductions

The challenges for the Battery Industry development for E-mobility in Europe

Speaker: C.Chanson – Recharge

Abstract:

The presentation will introduce a SWOT analysis of the challenges for the European battery

industry facing the e-mobility development. Strength and weaknesses will be reviewed in

the perspective of a Technical roadmap, an Industrial roadmap and a Business roadmap.

A special focus will be placed on the value chain of the battery for e-mobility, including the

impact of the recycling costs.

ELIBAMA project overview: from raw materials to manufacturing

Speaker: J.Peyrard - Renault

Abstract:

The global objective of the ELIBAMA project is to enhance and accelerate the creation of a

strong European automotive battery industry structured around industrial companies

already committed to mass production of Li-ion cells and batteries for EVs. By exploiting

advanced eco-design methods of manufacturing battery cells, the project aims at

guaranteeing drastic gains in cost reduction and environment-friendliness across the value

chain of the battery production.

This presentation will draw an overview of the ELIBAMA project’s context and highlight the

main results after 3 years of work.

Advanced manufacturing processes for Low Cost Greener Li-Ion batteries: the GREENLION

project

Speaker: I. Cendoya (IK4-CIDETEC)

Abstract:

GREENLION is a Large Scale Collaborative Project with the FP7 (topic GC.NMP.2011-1)

leading to the manufacturing of greener and cheaper Li-Ion batteries for electric vehicle

applications. Water soluble, fluorine-free and high thermally stable binders, which would

eliminate the use of VOCs and reduce the cell assembly cost are one of the key elements of

this project.

GREENLION has 6 key objectives whose current status and main results will be described:

• Development of new active and inactive battery materials viable for water processes • Development of innovative processes (coating from aqueous slurries) capable of

reducing electrode production cost and avoid environmental pollution

• Development of new assembly procedures (including laser cutting and high temperature pre-treatment) capable of substantially reduce the time and the cost of cell fabrication

• Lighter battery modules with and easier disassembly through eco-designed bonding techniques

• Waste reduction, which, by making use of the water solubility of the binder, allows the extensive recovery of the active and inactive battery materials

• Construction of fully integrated battery module for electric vehicle applications with optimized cells, modules, and other ancillaries

Innovative electrode materials and manufacturing processes

Special 3D copper foils to lower production costs for batteries

Speaker: H.Holeczek – Fraunhofer IPA

Abstract:

The aim for the use of 3D-structured anode foils for batteries is to decrease the production

time and to reduce the binder material.

An additional aim is to reduce the contact resistance between the active material and

conductor foils by special micro-roughness on the foil surface.

During the Elibama project a special production technology for copper foils was developed,

which fulfill these aims.

Green PVDF binder for green batteries

Speaker: M.Stanga – Solvay

Abstract:

New SOLEF® PVDF aqueous dispersions for Lithium Batteries: green PVDF for green

batteries

Solvay introduces a novel fluorinated binder in aqueous dispersion with proprietary

chemical modification for improved performance (in terms of adhesion and chemical

resistance) and a sustainable manufacturing process.

Solef® PVDF aqueous dispersions are specialty, environmentally-friendly PVDF grades

offered for use as water-based electrode binder in Li-ion batteries. Solef® PVDF aqueous

dispersions offer all the advantages of PVDF, while using a more environmentally-friendly

technology that allows to avoid the use of aggressive solvents, such as NMP, that are

required to dissolve PVDF resins.

Moreover, Solef® PVDF aqueous dispersions have intrinsically better molecular structure as

compared to standard PVDF, thanks to the chemically-modified PVDF polymer with

adhesion promoting sequences.

In negative electrode, taking advantage of PVDF binder high adhesion and lower volume at

equal weight compared to SBR, reduced amount of binder can be used in the formulation

increasing the amount of active material (to exploit the theoretical capacity and energy

density of the battery).

The challenge of an aqueous based and solvent free electrode coatings

Speakers: A.Glawe - Kroenert,

J.Breger – SAFT,

J.Peyrard - Renault,

M.CUdazzo - Fraunhofer

Abstract:

The coating is the hearth of the electrodes’ manufacturing process.

In the coming years, the constraints on organic solvents use will become stronger and

stronger.

The ELIBAMA project has worked on three innovative coating processes enabling to fully

avoid the NMP.

Innovative cells manufacturing processes

LiTFSI against LiPF6 : a losing battle ?.

Speaker: F.Metz – Rhodia - Solvay

Abstract:

For the design of an effective Li-ion battery, the nature of the lithium salt entering the

composition of the electrolyte is of paramount importance and has to fulfill many

requirements; in particular, the chemical and thermal stability of the Li salt, along with other

physical properties (ion mobility, ion pair dissociation, solubility, SEI formation…) is of crucial

importance.

Compared to the benchmark LiPF6, LiTFSI (lithium bis(trifluorosulphonyl)imide) displays

interesting physical and chemical properties, but its use in large scale batteries is hampered

by its manufacturing cost, markedly higher than that of LiPF6 due to a more complex

manufacturing process.

To address this problem, 2 tasks aiming to bring cost efficient and sustainable solutions for

large format batteries using the chemically and thermally stable lithium salt LiTFSI were

deployed within the ELIBAMA consortium :

1. Optimisation of the proprietary process for manufacturing potassium triflinate

(TFSK), key intermediate in the LiTFSI production.

2. Setting-up an effective recycling process for LiTFSI contained in LiTFSI based

batteries electrolytes.

The results obtained within these two topics will be presented and commented.

Assembly and Joining of Li-Ion-Cell Sheet-Stacks

Speaker: D.Lindenau - Daimler

Abstract:

Design, performance and costs of a Li-Ion-Cell depends on the accuracy, robustness and

effectiveness of every single step in stacking, assembly and joining of each component of

the cell. The cell stack and its joint to the cell contact have been identified as a key to

enhanced quality and active area.

New approaches and solutions are presented regarding handling, clamping and stacking the

coated sheets. In addition the results of fundament research on ultrasonic welding are

shown, that lead to a better seam quality using less space.

Process cleanliness control in Li-ion battery manufacturing: Impact of filtration and

purification solutions on battery production.

Speaker: C. Herriot (Entegris)

Abstract

In this presentation, a complete study of the contaminants found during battery

manufacturing is reported; metallic and non metallic particles were identified at different

production stages.

The methodology developed to detect the sources of contamination and their nature on the

whole line is explained. For each process step, the main sources of contamination were

classified into different categories. Among the different factors that contributed to

contamination, raw materials appeared critical: filtration and purification solutions were

implemented and the solution’s efficiency was measured. Finally, a significant impact of

filtration on 40 Ah battery cells was observed.

A Rapid Non-Destructive Testing Technique for Li-Ion Battery Quality Control.

Speaker: M. Armstrong (University of Newcastle)

Abstract

Quality control in production of automotive Li-ion cells is essential for both safety and

economic reasons. This paper presents a Non-Destructive Testing technique for automotive

scale, state-of-the-art, Li-ion battery cells. The aim of the test is to rapidly determine the

viability of a Li-ion cell within one minute. This is much faster than typical existing test

methods; at present, it is common industrial practice to store Li-ion batteries cells for up to

two weeks to analyse self-discharge performance.

The method proposed uses offline empirical data for benchmarking the cell response. This is

followed by a novel targeting process to enable rapid online testing. The applied technique

is a targeted form of electrochemical impedance spectroscopy (EIS) using a commercially

available potentiostat with EIS capability. The principle functionality of the method is

employed in the treatment of the offline empirical data library and the test made online. For

reasons of commercial sensitivity, no knowledge of the underlying cell chemistry is available

for use. Therefore, such information is not required to carry out the test. This demonstrates

the functionality of the proposed method across a range of different cell technologies and

its applicability to multiple battery technologies.

Eco-design tools and batteries end of life management

Life-Cycle Assessment in Lithium-ion batteries

Speaker: M. Gama (PE INTERNATIONAL)

Abstract

The ELIBAMA project had main focus in the development of new technologies for

manufacturing lithium ion batteries, in order to guarantee gains in cost reduction and

environment-friendliness across the value chain of the battery production. The

improvements were monitored and validated from the environmental point of view by an

integrated assessment, using LCA methodology, along the project. PE INTERNATIONAL had

an independent position, playing the moderator role among the consortium partners and

enhancing the communication from the different parts. Furthermore, PE provided the

battery manufacturers in the project with a flexible eco-design tool. The methodologies

used, the main challenges and results will be presented.

Toward an efficient batteries recycling process

Speaker: R. Laucournet (CEA)

Abstract

The end of life of Li-ion batteries is a key issue to respect the sustainability of the electrical

vehicles value chain. In Europe, this point is strictly framed by the directive 2006/66. This

regulation pushes pressure on batteries producers and therefore on recyclers to reach the

target of a fixed recycling efficiency which is 50 wt.%.

Through ELIBAMA project, partners involving in the task dedicated to the recycling: SNAM

(FR), Fraunhofer IPA Institute (GR), SOLVAY (FR) and CEA (FR) have identified several

improvement ways to overcome the limits of current processes. The given presentation will

show in a first part the main ways of Li-ion batteries recycling, the current limits and the

challenges that require effort. In a second part, the most significant results obtained in the

ELIBAMA project to increase the recycling materials efficiency will be presented and

perspectives to the project given.

Conclusions

An automotive battery industry in Europe: a chance to take?

Speaker: G.Patry - Renault

Abstract:

The industry of lithium-ion batteries is currently mainly localized in Asia: R&D centers as

production factories are principally in Japan, Korea and China, especially for automotive

applications. If this industry is already well developed, it has the potential to become

gigantic.

The aim of the project Elibama is to support the battery industry in Europe. If some major

players of the battery market are European, they are not able to compete against the

extremely powerful industrial group, as LG, Panasonic or Samsung on markets such as

batteries for electric vehicles. To understand the challenges behind a development and

production of lithium-ion batteries in Europe, several aspects are investigated herein. The

effect on cost of a European production in comparison with Asia is estimated. Then the

contribution of Elibama to reduce manufacturing cost is discussed. Finally, the interest of an

“Airbus of batteries” is studied.

BIOGRAPHIES

Matthew ARMSTRONG NEWCASTLE UNIVERSITY – Senior Lecturer Biography: Dr Matthew Armstrong is a Senior Lecturer in the School of Electrical and Electronic Engineering at Newcastle University, UK. He received M.Eng. and Ph.D. degrees from Newcastle University, UK in 1998 and 2006, respectively. Matthew has over 15 years’ experience in the field of control of electrical power. He has worked on a wide range of power electronic systems, from 50mW up to 150kW. His current research interests include system identification and parameter estimation of electrical systems, non-destructive testing and characterisation Li-Ion battery, real-time digital control of power electronic converters and electrical drive systems, and hardware-in-the-loop emulation systems. Much of his work is focused on practical application areas of key societal importance, such as electric vehicles and renewable energy system. Matthew currently supervises three post-doctoral researchers and twelve research students in the areas of system identification and control of power electronic systems. His work is funded from both industrial and research council sources. Matthew has published over 40 journal and international conference papers, and contributed to an IET Handbook on Electric Drives. He has presented at a number of International Conferences, and is also a regular reviewer for several international journals, including several IEEE Transactions and IET Proceedings.

Claude CHANSON RECHARGE association - General Manager Biography: Claude Chanson is Engineer in chemistry and physics from Bordeaux ENSCPB (1982) and has obtained a PHD in Electrochemistry in Bordeaux 1 University (1986). He previously served in Saft as an engineer in R & D and project manager in the telecommunications and automotive, before taking the office of Division Technical Manager and finally for Saft Group, the mission of Director of the Li-ion technology. He has moved to RECHARGE, representing the rechargeable battery industry interests with the Europeans Bodies, since 2 years.

Iosu CENDOYA GOITIA IK4-CIDETEC – Project Manager Biography: Mr. Iosu Cendoya Goitia. Industrial Engineer, School of Engineering of San Sebastian, University of Navarra (TECNUN), specialized in Electronics (2001). During 2001-2006 he worked for CEIT-TECNUN as Researcher in the field of passive integrated circuits. Since 2006 until 2011, he joined the industry as Project Technical Manager in INDAR Electric, focused on the design and manufacturing of wind generators. In 2011 he started his current job, as Project Manager in the Batteries Unit. His research is focused on the development of modules for stationary and traction applications based on Li-ion cells, covering the design and simulation fields.

Margarida GAMA PE INTERNATIONAL – Senior consultant Biography: Margarida Gama is senior consultant at PE INTERNATIONAL (Germany), having joined the company in 2010. Margarida is an expert on LCA and eco-design, working mainly within the consumer goods sector, especially in the fields of electronic and electro-mechanic products, as well as batteries. She is project manager and her recent activities include product-related environmental assessments, development of reporting and eco-design tools and studies to support the communication of sustainability policies. She has worked not only at company level, but also within industry associations and on EC projects.

Andrea GLAWE KROENERT GmbH & Co KG – R&D Director Biography: Education:

Study: 1992 Master degree for “Technical textiles and process technology” at the Technical University of Chemnitz

Professional Development:

1992 – 1993 Scientific assistant Textile Research Institute Plauen GmbH 1993 – 2001 Scientific assistant Textile Research Institute Thüringen-Vogtland e.V. Greiz 2001 – 2011 Coatema Coating Machinery GmbH, Dormagen Deputy sales director, technical sales and project manager 2011 – Feb. 2012 R&D leader DRYTEC GmbH & Co KG, Norderstedt Since March 2012 Director R&D KROENERT GmbH & Co KG, Hamburg

Cristelle HERRIOT ENTEGRIS – Application Engineer Biography:Cristelle Herriot is currently an Application Engineer at Entegris where she is in charge of the development of contamination control solutions for the energy market. She holds a PhD in Materials Science and Engineering obtained at the Paul Sabatier University (Toulouse, France). From 2006 to 2010, she worked in two different laboratories in US, Drexel University in Philadelphia and North Carolina State University in Raleigh: she focused her research on the development of new materials for energy storage systems such as supercacitors, Lithium ion batteries and fuel cells. She developed high energy anode electrodes at the CEA (Centre d’Energie Atomique) from 2010 to 2012.

Harald HOLECZEK FRAUNHOFER IPA – Senior project manager Biography: Harald Holeczek is a senior scientist and project manager at the Fraunhofer Institute for Manufacturing Engineering and Automation in Stuttgart, Germany. He is working in the Electroplating department and has been involved in the development of processes and specialized equipment for more than 15 years. He has published over 20 papers in that field. In the ELIBAMA project he was involved in the process development for 3D structured current collector foils and in the project management.

Richard LAUCOURNET CEA – Group head in the development of advanced materials for new energies Biography: Dr R. Laucournet (40 y): PhD in materials science in 2001 at Limoges University (FRANCE). He spent 7 years in the central research centre of PECHINEY (Alcan Rio Tinto) company in the field of primary aluminium production. In 2007, he joined CEA Grenoble as group head in the development of advanced materials for new energies. Since 2010, he is in charge of a research program focused on recycling of components for technologies of new energy mostly oriented on Li-ion batteries recycling. Now, recycling program led at CEA addresses more types of batteries for electric and hybrid vehicles (Ni-MH, Li-ion), photovoltaic panels, fuel cells, magnetic systems based on permanent magnets and PV panels.

Dirk LINDENAU DAIMLER – Joining technology powertrain manager Biography: Diploma in Mechanical Engineering (Manufacturing) University of Technology Aachen Fulbright grant to Arizona State University, USA, Industrial Engineering Doctoral thesis: “Magnetic effects on laser beam welding”, University Stuttgart Daimler AG since 2007 : joining and welding of body in white and gearboxes Since 2011: manager of team Joining Technology Powertrain

François METZ RHODIA-SOLVAY – Open Innovation responsible for the GBU Aroma Performance of the Solvay group Biography: François METZ is Master in chemistry and biochemistry from Strasbourg ULP (1980) and has obtained a PhD in Organic Chemistry in Strasbourg ULP (1985). He previously served in Rhône-Poulenc, then Rhodia and for now Solvay as an engineer in R & D and project manager in many fields (carbonylation, analytical chemistry, fluorine chemistry…). Since 2 years he serves as fluorination expert and is in charge of the Open Innovation for the GBU Aroma Performance of the Solvay group.*

Gaétan PATRY RENAULT – PhD Student Biography: Mr. Patry works since 3 years on modelling of the lithium-ion batteries cost, as a PhD Student. His work is hosted by the French car maker Renault, in collaboration with the university Arts et Métiers ParisTech and the French research laboratory CEA. He holds a master degree in chemical engineering from the Grenoble INP engineering school.

Jérôme PEYRARD RENAULT – Projects manager / ELIBAMA coordinator Biography: Jérôme Peyrard is graduated from the Ecole Centrale Paris. He started his industrial career in a French automotive supplier VALEO where he gained much experience in industrialization and project management with different European and non-European OEMs. He joined Renault in 2007: after some months as Manufacturing project Manager for thermal engine, he became responsible of the first industrialization of a battery pack for Renault (Fluence ZE). He is since January 2012 R&AE batteries projects manager and ELIBAMA coordinator.

Milena STANGA SOLVAY - Technical Marketing Engineer Biography: Milena Stanga is Technical Marketing Engineer for PVDF in Li Ion Battery at Solvay Specialty Polymers Italy. Milena holds a degree in Industrial Chemistry from University of Milan, Italy. She joined Solvay Solexis in 2000 and she worked first as polymerization expert for PVDF, focusing on polymerization process, polymerization recipes and polymer properties. She is co-inventor of several patents, and she currently is responsible for the development of new types of PVDF binders as well as separator.

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